Ingot mold teeming method



May 11, 1965 R. E. FERREE 3,182,363

INGOI' MOLD TEEMING' METHOD 7 Filed Oct. 3, 1962 NON-A UEOUS LIQUID 0AM INVENTOR.

ROY E. FERREE his ATTORNEY United States Patent 3,182,363 INGOT MOLD TEEMING METHOD Roy E. Ferree, Valencia, P2,, assignor to Eastern Splash-Mats Incorporated, Valencia, Pa. Filed Oct. 3, 1962, Ser. No. 228,002 6 Claims. (Cl. 22215) This invention relates to the pouring or teeming of molten steel into an ingot mold, however, it is also applicable to the pouring of other metals, both ferrous and non-ferrous.

An outstanding disadvantage resulting from the pouring of molten steel into an ingot mold is the accompanying splash, which is detrimental to the mold walls as well as to the surface qualities of the ingots. The mold walls Will erode from splash, also scabs are formed on the ingot, as well as oxidation due to exposure of the metal to the atmosphere as it is being poured.

An object of the present invention is to provide a novel process for pouring steel and other metals into an ingot mold that will eliminate the above-named disadvantages by eliminating or minimizing splash as well as oxidation.

A more specific object of the invention is to provide foam or a foam producing substance in an ingot mold so as to reduce splash and its eifects as well as to blanket the teemed metal from exposure to the atmosphere, thus eliminating oxidation.

Other objects and advantages of the invention will become more apparent from the following description taken with the accompanying drawing wherein the single figure is an elevational view partly in cross section showing a mold containing foam and into which molten steel is poured by a ladle.

The essence of the invention, as shown in the drawing is to provide foam in an ingot mold 3 which partially or entirely fills the mold so as to curb splash, since the foam breaks up the tendency of splashing. However, the type of materials for forming the foam are rather critical since the materials must be compatible with the particular molten metal being poured.

I have found that water-based foam is unsatisfactory whereas non-aqueous based foams are satisfactory, such as foam having a petroleum base. A specific composition that is very satisfactory for the purposes of the present invention is one comprising 1 to 2 parts of sulphuric acid, 8 parts of sodium carbonate and 8 parts of a carrier or solvent, such as kerosene, by volume. Another more satisfactory composition is 2 parts sulphuric acid, 8 parts sodium carbonate and 8 parts of a carrier or solvent such as trimethoxyboroxine which has a composition of (CH 0) B O Of course, these proportions may be varied somewhat without appreciably affecting the foaming qualities of the composition. Of course, other nonaqueous foam producing materials may be used instead, so long as they are compatible with the molten steel.

The foam may be either initially poured into the mold to fill or partially fill it before teeming or pouring of the molten metal-4 or it may be poured in while the metal is being poured. Alternatively, a foam-forming composition may be initially introduced into the mold which, as a consequence of the heat of the molten metal, will generate foam. In short, foam can be introduced or initiated in various ways, so long as it is present while molten steel or other metal is being poured.

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Such foam has been found to practically eliminate splash, therefore scabs on the ingot mold, as Well as oxidation since the foam blankets the metal being poured as well as the poured metal in the ingot mold from the surrounding atmosphere. Thus there results an ingot mold having surfaces free of defects and having a body devoid of non-desirable inclusions resulting from oxidation, so as to provide an amazing improvement in the qualities or characteristics of the resultant ingot.

In some cases, a foam-like material may be used instead such as steel wool or other material having a wooly or hair-like netting or mat simulating foam.

Thus it will be seen that I have provided an ellicient method for the pouring of molten steel which will eliminate or considerably reduce splash, scabbing, oxidation and similar defects attendant existing methods.

While I have described several embodiments of my invention, it will be understood that these are by way of illustration only, and that various changes and modifications may be made within the scope of the following claims.

I claim:

1. The method of pouring molten steel into an ingot mold which comprises introducing nonaqueous, liquid foam into the mold during pouring of the molten metal therein so as to minimize splash as well as oxidation.

2. The method of teeming steel and other metals which comprises at least partially filling an ingot mold with nonaqueous, liquid foam and thereafter pouring the molten metal into the foam-containing mold so as to eliminate splash and its attendant disadvantages.

3. The method recited in claim 2 wherein said foam has a petroleum base.

4. The method recited in claim 2 wherein said foam comprises the reaction product of substantially one part sulfuric acid, 8 parts of sodium carbonate and 8 parts of trimethoxyboroxine.

5. The method of teeming molten steel which comprises introducing a material into the mold and thereafter pouring molten metal on said material, which material will generate a nonaqueous liquid foam when mixed so as to produce sufficient foam in the mold as to minimize splashing as well as oxidation.

6. The method of teeming molten steel with minimum splash and oxidation, comprising introducing into the mold, prior to teeming, a nonaqeous, liquid foam-like material sufiicient for blanketing outside air and for minimizing splash and thereafter pouring the molten steel into said mold on said material.

References Cited by the Examiner UNITED STATES PATENTS 2,830,343 4/58 Shroyer 22-196 2,869,197 1/59 Patterson 22-139 FOREIGN PATENTS 1,052,438 9/53 France.

1,092,373 11/54 France.

MARCUS U. LYONS, Primary Examiner.

MICHAEL V. BRINDISI, Examiner. 

1. THE METHOD OF POURING MOLTEN STEEL INTO AN INGOT MOLD WHICH COMPRISES INTRODUCING NONAQUEOUS, LIQUID FOAM INTO THE MOLD DURING POURING OF THE MOLTEN METAL THEREIN SO AS TO MINIMIZE SPLASH AS WELL AS OXIDATION. 